Concrete building structures with prelaminated plasterboard facing sheets



G. .J1 SELL 3,344,572

-LAMINATED Oct. 3, 1967 CONCRETE BUILDING STRUCTURES WITH PRE PLASTERBOARD FAGING SHEE Filed Jan. 4, 1955 FIGJZv FIClv /A/ VEN TOR Geo/*ge `fdr/7.25 Se# 5 Y W M KQ@ ATTOQA/EXS United States Patent O CONCRETE BUILDING STRUCTURES WITH PRE- LAMINATED PLASTERBOARD FACING SHEETS George James Sell, Bishops Stortford, England, assignor to Trusteel Corporation (Universal) Ltd.

Filed Jan. 4, 1965, Ser. No. 423,129 Claims priority, application Great Britain, Jan. 4, 1964, 471/64 1 Claim. (Cl. 52-426) ABSTRACT F THE DISCLOSURE Vertical members set in a common base, each having spaced pairs of flanges with a vertical recess between the flanges of each pair receiving and retaining fastening means by which plasterboard sheets are secured, in spaced relation, to the vertical members and defining a molding cavity between metal foil on the facing surfaces of the sheets, a core of no-lines concrete being set in said cavity.

The present invention relates to building constructions and in particular to wall constructions formed from concrete.

An object of the present invention is to provide a wall, for example, a party wall, which can be load bearing, and which has good sound and heat-insulating properties. It is also an object to provide a wall which has cladding material on both surfaces.

The invention will be more clearly understood from the following description of an embodiment thereof, and the accompanying drawing in which:

FIG. 1 is an isometric view, partly cut away, of a party wall according to the invention;

FIG. 2 is a detail View showing the manner in which the laminated cladding is secured to the upright member.

The framework for the wall comprises a series of stanchions or uprights 1, suitably of steel, which are mounted on a suitable base or foundation 8 and which reach to a ceiling level at which they support a beam (not shown). This beam may in turn support uprights similar to the uprights 1 for the second storey.

Each of the uprights 1 is an I-section girder. The end webs forming the lateral edges of the girder each comprise a pair of aligned flanges 3 which are spaced apart to provide a gap or channel 6 for a purpose described below. The part of the centre web 4 inwardly of the portions providing the channels 6, is an openwork structure 4 which could take forms for example, a lattice structure, other than as shown. The outer edges of the flanges 3 are inturned at 5.

The base 8 on which the stanchions 1 are erected suitably comprises a pre-moulded concrete foundation beam which underlies the wall. The beam 8 rests on foundation pad 21 or other suitable foundation, for example, short bored piles. The stanchions 1 are secured to the beam 8 by angle brackets 22 which are bolted into holes in the beam preformed at suitable spacings.

When the stanchions 1 are in place, sheet 25, of cladding material, are applied and secured to them.

The `cladding material 25 comprises pre-laminated plasterboard which is fixed to the end-webs by means of selftapping screws (not shown) which engage in the screw gaps 6. No-nes concrete 24 is then poured in and hand compacted to ensure that the cavity is completely filled. This effectively completes the construction steps, the concrete now being merely allowed to set hard and the external surfaces of the cladding being eventually decorated ice as desired. Further storey heights can be cast subsequently in a similar way. It will be appreciated that the cladding material 25 must be made impervious to the moisture in the no-fines concrete as this will otherwise creep through the material and spoil the external face. The pre-laminated plasterboard mentioned above is therefore provided on its inner surface 26 with a layer of metal foil which additionally functions to provide a degree of thermal insulation.

The channels 6 may be sealed, for example, by being plugged with neoprene or other suitable sealing material, or by being covered by a suitable self-adhesive tape. Such sealing means can be applied to the stanchions during the manufacturing stage; if tape is used, it need never be removed, as screws or like securing means can readily penetrate it.

When the wall extends to an outer face of the building, the end of the mould cavity at this face can be closed by applying a permanent external cladding member, in the form of an upright connected to panels 23 or Aby means of such panels.

After the concrete wall has been built up to the first oor, the moulding operation is repeated on the next floor and may be further repeated on any further floors.

The openwork structure of the stanchions permits continuity of the concrete, or other settable material, for the length and height of the wall.

Among the advantages afforded by the invention, is that no temporary scaffolding has to be erected for forming the wall. The stanchions, which constitute the framework of the building itself, take the place of temporary scaffolding, besides providing, when once embedded into the core, reinforcement for the concrete.

The invention is particularly but not exclusively applicable to the construction of party walls, for example, between semi-detached or terraced houses having a steel or other frame structure onto which cladding material is required to be applied. The invention provides in such an application a party wall with good heat and sound insulation properties and which is also resistant to fire. The invention also provides a party wall which is load bearing, so that it can support flooring and roofing elements.

It will be appreciated that the embodiment specifically described above is merely exemplary of the invention as applied to a particular steel framed building system. The invention can lbe employed with advantage with other systems, and the embodiment described can be modified in a variety of ways, as will be apparent to those skilled in the art, within the scope of the following claim.

What I claim is:

A wall comprising a plurality of upright members set in a common base, each of said members having first and second spaced and oppositely facing flanges, and each of said first and second flanges including means defining a recess for receiving and retaining fastening means, cladding comprising pre-laminated plasterboard sheets, each lined on one face thereof with metal foil, fastening means engaging with said recesses in said rst and second flanges, said fastening means removably securing a first set of said plasterboard sheets with said lined faces in engagement with said first flanges, and removably securing a second set of said plasterboard sheets with said lined faces in engagement with said second flanges, said first and second sets of plasterboard sheets defining a mould cavity between the lined faces thereof, and a core of no-flnes concrete set in said cavity, said upright members being embedded in said core.

(References on following page) 3 4 References Cited 2,356,309 8/ 1944 Garbe 52--236 X UNITED STATES PATENTS 3,186,131 6/1965 Denny et a1. 52-461 X s/1909 Pelton 52-250 X FOREIGN PATENTS 4/1910 Lawrence 52--380 X 5 336,567 10/1930 Great Britain. 5/1921 Dargento 52-378 X 755,951 8/1956 Great Britain. 7/1926 Lawrence 52-259 413,153 3/1946 Italy. 5/ 1929 Pedersen 52.-258 4/1936 Oliver 52 250 X FRANK L. ABBOTT, Primary Examiner. 8/ 1941 Pelton 52-422 lo A. C. PERHAM, Assistant Examiner. 

